STARGATE SG-1 - Ori helmets

I have been comissionned by the original production molds owner to make a limited run of the ori commander and soldier helmets .
Each set of molds produce different helmets, the one which cover the face is the soldier helmet, the other one is the commander helmet.

The process on these mold is rotocasting ; slushing resin and moving the mold in order to cover the inside of it until fair thickness.
It has to be done layer per layer in order to get an even coverage all the way, layer must not be fully cured or it might end up the with layer not bonding to the previous one.
I used PU84 poylurethane resin from Esprit composite for this project, pot life is 4 minutes with 1 hour demold time, which suit perfectly my need for those molds.

First layer is tinted black and slushing all inside the mold, i used black tint in order to save paint, as black is the base color i needed for paint purposes later.
Layers after that were mixed with shredded fiber, gives a durable casting.

Third layer was tinted black again, but on this one i previously lay down some fiber on the previous partially cured layer, then slushed the third layer, the goal is to give strenght to the helmet, it allows to reduce the amount of resin, so it’s lightweight and strong.